Seamlessly knitted structure and a male garment comprising the same

ABSTRACT

The present disclosure generally relates to a seamlessly knitted structure ( 100 ) for a male garment ( 200 ), the knitted structure ( 100 ) comprising: a main fabric layer ( 110 ); a support fabric layer ( 120 ) knitted to the main fabric layer ( 110 ), the support fabric layer ( 120 ) formed of a stiffer material than the main fabric layer ( 110 ); and a pouch fabric layer ( 130 ) knitted to and extending outwardly from the main fabric layer ( 110 ) and supported by the support fabric layer ( 120 ), the pouch fabric layer ( 130 ) forming a pouch space for accommodating a groin region of a male user wearing the male garment ( 200 ) comprising the knitted structure ( 100 ).

CROSS REFERENCE TO RELATED APPLICATION(S)

The present disclosure claims the benefit of Singapore Patent Application No. 10202011258Q filed on 12 Nov. 2020, which is incorporated in its entirety by reference herein.

TECHNICAL FIELD

The present disclosure generally relates to a seamlessly knitted structure for a male garment. More particularly, the present disclosure describes various embodiments of the knitted structure, the male garment comprising the knitted structure, and a method for producing the knitted structure.

BACKGROUND

There are various types of male garments, specifically undergarments such as boxers and jockstraps. Boxers are commonly produced using traditional cut and sew constructions which result in unsightly stitches and seams at the groin region that can be uncomfortable for the male user wearing the boxer. A jockstrap has an elastic waistband with a support pouch for the groin region and elastic straps joining the support pouch to the waistband. These components of the jockstrap are separately formed and joined together, resulting in unsightly and uncomfortable joints at the groin region like the boxers.

Therefore, in order to address or alleviate at least one of the aforementioned problems and/or disadvantages, there is a need to provide an improved male garment.

SUMMARY

According to a first aspect of the present disclosure, there is a seamlessly knitted structure for a male garment, knitted structure comprising: a main fabric layer; a support fabric layer knitted to the main fabric layer, the support fabric layer formed of a stiffer material than the main fabric layer; and a pouch fabric layer knitted to and extending outwardly from the main fabric layer and supported by the support fabric layer, the pouch fabric layer forming a pouch space for accommodating a groin region of a male user wearing the male garment comprising the knitted structure.

According to a second aspect of the present disclosure, there is a male garment comprising a fabric body and the knitted structure joined to the fabric body.

According to a third aspect of the present disclosure, there is a method of producing the knitted structure, the method comprising seamlessly knitting the knitted structure using a knitting machine.

A knitted structure for a male garment according to the present disclosure is thus disclosed herein. Various features, aspects, and advantages of the present disclosure will become more apparent from the following detailed description of the embodiments of the present disclosure, by way of non-limiting examples only, along with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a seamlessly knitted structure for a male garment, in accordance with some embodiments of the present disclosure.

FIGS. 2A and 2B are illustrations of the male garment comprising the knitted structure at a front panel of the male garment, in accordance with some embodiments of the present disclosure.

FIG. 3 is an illustration of the male garment comprising the knitted structure, in accordance with some other embodiments of the present disclosure.

FIGS. 4A and 4B are illustrations of a back panel of the male garment, in accordance with some other embodiments of the present disclosure.

DETAILED DESCRIPTION

For purposes of brevity and clarity, descriptions of embodiments of the present disclosure are directed to a seamlessly knitted structure for a male garment, in accordance with the drawings. While aspects of the present disclosure will be described in conjunction with the embodiments provided herein, it will be understood that they are not intended to limit the present disclosure to these embodiments. On the contrary, the present disclosure is intended to cover alternatives, modifications and equivalents to the embodiments described herein, which are included within the scope of the present disclosure as defined by the appended claims. Furthermore, in the following detailed description, specific details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be recognized by an individual having ordinary skill in the art, i.e. a skilled person, that the present disclosure may be practiced without specific details, and/or with multiple details arising from combinations of aspects of particular embodiments. In a number of instances, well-known systems, methods, procedures, and components have not been described in detail so as to not unnecessarily obscure aspects of the embodiments of the present disclosure.

In embodiments of the present disclosure, depiction of a given element or consideration or use of a particular element number in a particular figure or a reference thereto in corresponding descriptive material can encompass the same, an equivalent, or an analogous element or element number identified in another figure or descriptive material associated therewith.

References to “an embodiment/example”, “another embodiment/example”, “some embodiments/examples”, “some other embodiments/examples”, and so on, indicate that the embodiment(s)/example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment/example necessarily includes that particular feature, structure, characteristic, property, element or limitation. Furthermore, repeated use of the phrase “in an embodiment/example” or “in another embodiment/example” does not necessarily refer to the same embodiment/example. The terms “comprising”, “including”, “having”, and the like do not exclude the presence of other features/elements/steps than those listed in an embodiment. Recitation of certain features/elements/steps in mutually different embodiments does not indicate that a combination of these features/elements/steps cannot be used in an embodiment. As used herein, the terms “a” and “an” are defined as one or more than one. The use of “/” in a figure or associated text is understood to mean “and/or” unless otherwise indicated. The terms “first”, “second”, etc. are used merely as labels or identifiers and are not intended to impose numerical requirements on their associated terms.

In representative or exemplary embodiments of the present disclosure, as shown in FIG. 1 , there is a seamlessly knitted structure 100 for a male garment 200, such as undergarments like boxers. Further as shown in FIGS. 2A and 2B, the male garment 200 comprises a fabric body 210 and the knitted structure 100 joined to the fabric body 210. The knitted structure 100 comprises a main fabric layer 110 and a support fabric layer 120. The support fabric layer 120 is knitted to the main fabric layer 110. The support fabric layer 120 is formed of a stiffer material than the main fabric layer 110, i.e. the support fabric layer 120 is formed of a high modulus material. The knitted structure 100 further comprises a pouch fabric layer 130 knitted to and extending outwardly from the main fabric layer 110 and the pouch fabric layer 130 is supported by the support fabric layer 120. More specifically, the pouch fabric layer 130 is knitted to the main fabric layer 110 via the support fabric layer 120 that interfaces between the pouch fabric layer 130 and main fabric layer 110. The pouch fabric layer 130 forms a pouch space for accommodating the groin region of a male user wearing the male garment 200 comprising the knitted structure 100.

The main fabric layer 110, support fabric layer 120, and pouch fabric layer 130 are knitted continuously and seamlessly such that there are no seams around the knitted structure 100. The knitting may be performed using a knitting machine such as a flatbed knitting machine, particularly a V-bed flat knitting machine. Embodiments of the present disclosure also describe a method of producing the knitted structure 100 for the male garment 200, the method comprising seamlessly knitting the knitted structure 100 using the knitting machine.

In some embodiments, the knitted structure 100 is separately formed and later joined to a front panel 220 of the fabric body 210 of the male garment 200 as shown in FIG. 2A, such as by sewing, stitching, adhesive, or bonding. The front panel 220 and back panel 230 (as shown in FIG. 2B) of the fabric body 210 are then joined together, such as by sewing, stitching, adhesive, or bonding, to form the male garment 200. Alternatively, the front panel 220 and back panel 230 may be knitted continuously as a single fabric panel and then joined at both edges with one seam. The fabric body 210 comprising the front panel 220 and back panel 230 may be in the form of a plated structure having main yarns and plating yarns. In some embodiments, the knitted structure 100 is seamlessly knitted together with the front panel 220, and the front panel 220 comprising the seamless knitted structure 100 is then joined with the back panel 230 to form the male garment 200. In some embodiments, the knitted structure 100 is seamlessly knitted together with the front panel 220 and back panel 230 to form a seamless male garment 200.

When the male garment 200 comprising the seamlessly knitted structure 100 is worn by the male user, the seamless construction of the knitted structure 100 results in significantly reduced chafing at the groin region, thus improving comfort during all day wear and especially during movement. The seamless construction also results in a more durable product, especially with frequent washing and wearing, as the seams are often the weakest part of a garment produced using the traditional cut and sew constructions.

The main fabric layer 110 can be formed of any knit design, such as a single jersey knit structure or a pique knit structure. In some embodiments, the main fabric layer 110 comprises a mesh or porous structure that provides ventilation and improves breathability. The main fabric layer 110 may comprise any type of yarn, such as but not limited to, filament yarn, short staple spun yarn, nylon yarn, polyester yarn, polypropylene yarn, cotton yarn, wool yarn, and regenerated yarn.

In some embodiments, the main fabric layer 110 comprises frictional yarns or high friction yarns. Knitting of the main fabric layer 110 using frictional yarns can mitigate the tendency of the male garment 200 riding up the user's thighs when the user is moving. This riding up can occur because during movement, the male garment 200 is subject to external forces which can lead to a shift in position of the male garment 200 upwards along the thighs.

The frictional yarns may be knitted along peripheral edges 112 of the main fabric layer 110. These peripheral edges 112 may coincide with the hem area 212 of the male garment 200 where the knitted structure 100 is joined to the fabric body 210. The hem area 212 may include a microfiber structure to similarly mitigate the riding up issue. The frictional yarns may be alternatingly knitted with the yarns of the fabric body 210 at the hem area 212 to seamlessly knit and integrate the knitted structure 100 with the fabric body 210. The hem area 212 may comprise a tube knit. The frictional yarns may comprise one or more of nano yarns/fibres, micro yarns/fibres, and silicone yarns/fibres.

The support fabric layer 120 is arranged to support the pouch fabric layer 130 that forms the pouch space or 3D pouch for accommodating the groin region of the user wearing the male garment 200. The support fabric layer 120 is formed of a stiffer material than the main fabric layer 110, i.e. a high modulus material, so that the support fabric layer 120 is able to provide sufficient support for the pouch fabric layer 130 and consequently for the groin region. The support fabric layer 120 may be knitted in the form of a double jersey knit structure, spacer structure, or plated structure. The pouch fabric layer 130 may be knitted in the form of a single jersey knit structure. Further, the pouch fabric layer 130 may be knitted using the holding down knitting technique to create the required volume of the pouch space. The support fabric layer 120 and pouch fabric layer 130 can be knitted or formed according to desired/customized requirements, enabling the male garment 200 to be personalized to customer needs.

The support fabric layer 120 comprises yarns made of a high modulus material and/or having a high GSM value. The high modulus material may include spandex, elastane, rubber (natural or synthetic), or thermoplastic polyurethane (TPU) which would limit stretching of the yarns. The yarns may include but are not limited to single covered yarns, doubled covered yarns, mechanical stretch yarns. Notably, the material of the support fabric layer 120 is stiffer or has a higher modulus than the material of the main fabric layer 110, meaning that a larger force is required to stretch one unit length of the support fabric layer 120 compared to the main fabric layer 110.

In some embodiments, the knitted structure 100 comprises a functional layer 140 knitted to the pouch fabric layer 130 and disposed within the pouch space. Similarly, the functional layer 140 is seamlessly knitted to the pouch fabric layer 130 such that the knitted structure 100 is seamless. The functional layer 140 is configured for various functionalities such as for absorbing and/or wicking moisture. For example, the functional layer 140 comprises an absorbent/wicking material to absorb and wick moisture away from user. For example, the absorbent/wicking material may be cotton, rayon, polycotton, or poly rayon. The functional layer 140 may comprise a double jersey knit structure, spacer structure, or plated structure to provide additional support for the pouch fabric layer 130. Having the absorbent/wicking functional layer 140 can address certain conditions that the user may suffer from, such as urinary incontinence.

It will be appreciated that knitting of the knitted structure 100 can be done in the vertical direction or horizontal direction. For example, a draw thread 150 is knitted in the knitted structure 100 for dividing the knitted structure 100 if the knitted structure 100 is knitted in the left-right or right-left direction. The knitted structure 100 can be joined or stitched to the fabric body 210 of the male garment 200 after removing the draw thread 150. It will also be appreciated that different knit designs may be formed in any area of the knitted structure 100 and fabric body 210 of the male garment 200.

FIG. 3 illustrates an alternative embodiment of the male garment 200 comprising the knitted structure 100 in the front panel 220 of the fabric body 210. The main fabric layer 110 may include first fabric areas 114 adjacent to both sides of the support fabric layer 120. The first fabric areas 114 are arranged such that when the male garment 200 comprising the knitted structure 100 is worn, the first fabric areas 114 are aligned to the groin region and inner thigh regions of the user. The first fabric areas 114 may be made of a smooth or low friction material to reduce chafing at the inner thigh regions, especially when the thighs come into contact together during movement.

The main fabric layer 110 may include second fabric areas 116 adjacent to the first fabric areas 114. The second fabric areas 116 start from the top and sides of the main fabric layer 110 and extend downwards and inwards and at angle to the bottom. The second fabric areas 116 are arranged such that when the male garment 200 comprising the knitted structure 100 is worn, the second fabric areas 116 are aligned to the sartorius muscles in the thighs of the user. The second fabric areas 116 separate the first fabric areas 114 and the fabric body 210 of the male garment from each other, allowing them to move independently. The second fabric areas 116 may have a mesh or porous structure which increases the frictional forces with the skin, reducing the tendency for the male garment 200 to shift in position during movement. The second fabric areas 116 may be made of a high modulus or substantially inelastic material, i.e. a material that is non-elastic or has low elasticity. Alternatively or additionally, the second fabric areas 116 include frictional yarns or a high frictional material to increase the frictional forces.

The main fabric layer 110 may include third fabric areas 118 between the first fabric areas 114 and the support fabric layer 120. The third fabric areas 118 may have a mesh or porous structure to provide additional ventilation and improved breathability.

The back panel 230 of the fabric body 210 may include additional features to improve support of the garment 200 for the user. In one embodiment as shown in FIG. 4A, the back panel 230 is knitted with pockets 232. Padded layers can be inserted into the pockets 232 to shape the back panel 230 and provide support and comfort to the butt area of the user. In one embodiment, the back panel 230 is knitted with a thicker material or structure, such as double jersey knit structure, spacer structure, or plated structure, to shape the back panel 230 and achieve the padded butt lift effect. In one embodiment as shown in FIG. 4B, the back panel 230 is knitted with a stiffer or high modulus material to shape various areas 234 of the back panel 230 not limited to the butt area. In one embodiment, the back panel 230 includes a mesh or porous structure to provide ventilation at the butt area of the user.

It will be appreciated that various features of the embodiments as described in FIGS. 2A, 2B, 3, 4A, and 4B can apply similarly or analogously to one another.

Accordingly, embodiments herein describe the seamlessly knitted structure 100 and male garment 200 comprising the knitted structure 100. Various parts of the knitted structure 100 are seamlessly knitted together to produce a seamless product that can provide support for the groin region and superior comfort to the user. Additional functionalities can be provided, such as moisture absorbency and wicking, with a suitable absorbent and wicking layer seamlessly knitted with the knitted structure 100. Moreover, the riding up issue has been addressed by the knitted structure 100 and male garment 200 with suitable fabric arrangements and materials. The male garment 200 can be produced as standard everyday men's boxers or as performance boxers for sportsmen. For example, the male garment 200 for making performance boxers may include covered yarns with spandex cores as the main yarns in the fabric body 210.

In the foregoing detailed description, embodiments of the present disclosure in relation to a seamlessly knitted structure for a male garment are described with reference to the provided figures. The description of the various embodiments herein is not intended to call out or be limited only to specific or particular representations of the present disclosure, but merely to illustrate non-limiting examples of the present disclosure. The present disclosure serves to address at least one of the mentioned problems and issues associated with the prior art. Although only some embodiments of the present disclosure are disclosed herein, it will be apparent to a person having ordinary skill in the art in view of this disclosure that a variety of changes and/or modifications can be made to the disclosed embodiments without departing from the scope of the present disclosure. Therefore, the scope of the disclosure as well as the scope of the following claims is not limited to embodiments described herein. 

1. A seamlessly knitted structure for a male garment, the knitted structure comprising: a main fabric layer; a support fabric layer knitted to the main fabric layer, the support fabric layer formed of a stiffer material than the main fabric layer; and a pouch fabric layer knitted to and extending outwardly from the main fabric layer and supported by the support fabric layer, the pouch fabric layer forming a pouch space for accommodating a groin region of a male user wearing the male garment comprising the knitted structure.
 2. The knitted structure according to claim 1, wherein the support fabric layer comprises a double jersey knit structure, a spacer structure, or a plated structure.
 3. The knitted structure according to claim 1, further comprising a functional layer knitted to the pouch fabric layer and disposed within the pouch space.
 4. The knitted structure according to claim 3, wherein the functional layer is configured for absorbing and/or wicking moisture.
 5. The knitted structure according to claim 1, wherein the main fabric layer comprises frictional yarns along peripheral edges of the main fabric layer.
 6. The knitted structure according to claim 1, wherein the main fabric layer comprises a mesh or porous structure.
 7. The knitted structure according to claim 1, wherein the main fabric layer comprises first fabric areas adjacent to the support fabric layer, such that when the male garment is worn by the male user, the first fabric areas are aligned to the groin region and inner thigh regions of the male user.
 8. The knitted structure according to claim 7, wherein the first fabric areas comprise a smooth material.
 9. The knitted structure according to claim 7, wherein the main fabric layer comprises second fabric areas adjacent to the first fabric areas, such that when the male garment is worn by the male user, the second fabric areas are aligned to the sartorius muscles of the male user.
 10. The knitted structure according to claim 9, wherein the second fabric areas comprise a mesh or porous structure.
 11. The knitted structure according to claim 9, wherein the second fabric areas comprise a substantially inelastic material and/or frictional yarns.
 12. A male garment comprising a fabric body and the knitted structure according to claim 1, wherein the knitted structure is joined to the fabric body.
 13. The male garment according to claim 12, wherein the knitted structure is stitched to the fabric body.
 14. The male garment according to claim 12, wherein the knitted structure is seamlessly knitted together with the fabric body.
 15. A method of producing the knitted structure according to claim 1, the method comprising seamlessly knitting the knitted structure using a knitting machine.
 16. The method according to claim 15, wherein the knitting machine is a V-bed flat knitting machine. 